Improved Solidification Shrinkage Model

One of the standout upgrades in 2025R1 is the enhanced shrinkage porosity model. By capturing more nuanced thermal and metallurgical behaviors during solidification, the software now provides even more accurate predictions of shrinkage-related defects. This results in higher fidelity simulations, allowing foundry engineers to proactively adjust gating systems, risers, and cooling channels before a single mold is poured.

 EXODUS Format Output for Porosity Data

For users who need advanced post-processing and integration with third-party tools, FLOW-3D CAST 2025R1 now supports outputting shrinkage and gas porosity data in the EXODUS file format. This enables improved compatibility with FEA tools, supports detailed leak path analyses, and allows engineers to visualize and track defects in more intuitive ways across platforms.

 Enhanced Shot Sleeve Modeling for High-Pressure Die Casting (HPDC)

The HPDC workspace has seen a major advancement. FLOW-3D CAST now simulates the behavior of solidified metal inside the shot sleeve, an often-overlooked element that plays a critical role in thermal transfer and defect formation. By accounting for this factor, engineers can better predict cold shuts, incomplete fills, and misruns—key defects in HPDC processes.

 More Accurate Valve and Vent Modeling

Venting and valve control are essential for preventing trapped gases and achieving clean, defect-free castings. In FLOW-3D CAST 2025R1, users can now define specific target metal volumes for vents and simulate more realistic valve behaviors. This provides better control over air evacuation and supports advanced strategies for minimizing gas porosity and oxide formation.

 Streamlined Process-Specific Workspaces

With 11 specialized workspaces for common casting processes—including sand casting, investment casting, tilt pour, centrifugal casting, lost foam, and low-pressure die casting—FLOW-3D CAST continues to simplify simulation setup and reduce learning curves. Each workspace includes tailored templates, physics models, and mesh generation settings for fast and accurate simulation development.